Foldable Display Outer Structure With Modulus-Graded Layers
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Solution Overview
Problem
The increasing complexity and cost of fabricating display devices, particularly in the development of bendable and foldable display devices, are exacerbated by the need to assemble various parts as modules, leading to significant dead space and reduced durability.
Innovation Solution
A display device design featuring a display module surrounded by an outer structure with varying Young's modulus layers, where the first outer layer has a lower modulus than the second, and a method of fabrication involving separate molds for forming these layers to minimize dead space and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If display devices are fabricated as modular assemblies to reduce complexity and cost, then manufacturing ease improves, but dead space between modules increases and structural integrity deteriorates
Solution Approach 1:
The patent applies a flexible outer structure comprising multiple layers (including a flexible substrate and protective layers) that envelops the display module. This flexible shell design allows the structure to conform closely to the module contours, minimizing dead space while maintaining modular assembly benefits. The flexible nature enables smooth transitions between modules without rigid gaps.
Solution Approach 2:
The outer structure utilizes composite material construction with multiple functional layers including flexible substrates, protective coatings, and adhesive layers. This composite approach allows optimization of each layer for specific functions while collectively achieving reduced dead space and improved structural integrity without compromising modular fabrication ease.
2Ease of manufacture
If display devices are fabricated as modular assemblies to reduce complexity and cost, then manufacturing ease improves, but durability deteriorates
Solution Approach 1:
The outer structure employs a multi-layer composite construction including flexible substrates, protective layers, and adhesive layers. Each layer contributes specific properties: flexibility for bending, protection for durability, and adhesion for structural integrity. This composite approach maintains modular fabrication ease while significantly improving overall device durability and reliability.
Solution Approach 2:
The patent incorporates protective layers within the outer structure that provide beforehand cushioning and protection to the display module. These layers are designed to absorb and distribute mechanical stresses before they reach critical components, thereby enhancing durability while maintaining the modular assembly structure.
3Strength
If a single rigid outer structure is used to surround the display module, then structural integrity improves, but flexibility and folding capability deteriorate
Solution Approach 1:
The patent replaces rigid outer structures with a flexible outer structure comprising multiple layers including a flexible substrate. This flexible shell maintains structural integrity through its layered construction while enabling bending and folding movements. The flexibility allows the structure to adapt to dynamic configurations without compromising strength.
Solution Approach 2:
The outer structure is designed with dynamic characteristics, allowing it to transition between rigid and flexible states. The multi-layer construction with adhesive layers provides structural integrity during normal use, while the flexible substrate enables bending and folding when required, making the structure adaptable to different operational states.
4Ease of manufacture
If outer structure layers have uniform mechanical properties, then manufacturing simplicity improves, but performance optimization deteriorates
Solution Approach 1:
The outer structure employs different layers with locally optimized properties: flexible substrates for bendability, protective layers for durability, and adhesive layers for bonding. Each layer has specific mechanical properties tailored to its function. While this creates manufacturing complexity, it significantly improves overall reliability by balancing flexibility and durability requirements that cannot be achieved with uniform materials.
Data Source
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AI summary
A display device include a display module and an outer structure surrounding the display module. The display module includes: a display panel having a folding area and a non-folding area at a side of the folding area; an upper module on an upper side of the display panel; and a lower module on a lower side of the display panel. The outer structure includes: a first outer layer adjacent to the display module; and a second outer layer on an outer side of the first outer layer. A Young's modulus of the first outer layer is different than a Young's modulus of the second outer layer.